Mold system for forming multilevel blocks

ABSTRACT

A mold system for forming a multilevel block is disclosed which comprises a multilevel mold box insert for forming a multilevel block, a mold box frame adapted for receiving therein the multilevel mold box insert, a multilevel plunger assembly, and a press head plate adapted for receiving thereon the multilevel plunger assembly.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 13/136,275, which was filed on Jul. 27, 2011.

BACKGROUND

This disclosure relates to a mold system and more particularly to a moldsystem for forming multiple tiered blocks such as an edging comprising alow edge surface upon which a lawn mower may ride or travel when cuttinggrass and a high edge surface for retaining landscape elements such asmulch or rock. Further, a multilevel mold system is disclosed that canbe used in a block or paver machine to manufacture various shapedmultilevel or multiple tiered blocks.

The landscaping of residential and commercial properties can include alawn in combination with various other landscaping structures. Forexample, a grass lawn may encompass a majority of the landscaping withtrees and a planting bed being interspersed in the grass lawn. In thiscase, a border may be formed between the grass lawn and the trees andthe planting bed. The border may be constructed using various materialssuch as railroad ties, rocks, blocks, and plastic edging. Although suchborders are decorative, they pose a problem when cutting the grass lawn.In particular, there is an edge between the grass lawn and the borderwhich is difficult to cut by use of lawn mowing equipment and requirestrimming of the edge so that the height of the grass in the edge is thesame as the height of the grass in the lawn. Trimming is time consumingand requires additional equipment to trim the edge. Although there havebeen various edging systems proposed, such systems have disadvantages.For example, such systems are difficult for a homeowner to install andrequire a professional installation. A professional installation adds tothe cost of the system. Also, some of the edging systems are expensiveto manufacture which adds to the cost of installing the system. Anotherdisadvantage is that the edging systems do not lock or hold the edgingsystem in place. In view of this, such systems are subject to failureand need to be replaced or completely removed. Another disadvantage isthat the edging systems do not allow for the construction of differentshaped borders. In particular, only a few border configurations may beconstructed. For example, some edging systems only provide for theinstallation of a rectangular shaped border. If a rounded border isdesired then the edging system may not be used. Further, if an irregularshaped border, such as a kidney shaped border, is required then suchedging systems are not capable of forming an irregular shaped border.

Although these landscape edging blocks are useful, such blocks aredifficult to manufacture because they are multilevel blocks. Therefore,it would be desirable to have a mold system that is capable ofmanufacturing various shaped multilevel blocks that are versatile andadapted to form any shape or configuration required in a landscapedarea. The mold system of the present disclosure is also capable offorming different shaped blocks during the same manufacturing process.It would also be advantageous to have a mold system that can manufacturemultilevel blocks that can be locked in place and are easy to install byboth professionals and homeowners. Moreover, the mold system of thepresent disclosure can be employed to produce multilevel blocks that canbe easily used to construct various complex landscaping configurationswith a small number of blocks comprising the landscape edging system.

BRIEF SUMMARY

In one form of the present disclosure, a mold system for forming amultilevel block comprises a multilevel mold box insert for forming amultilevel block, a mold box frame adapted for receiving therein themultilevel mold box insert, a multilevel plunger assembly, and a presshead plate adapted for receiving thereon the multilevel plungerassembly.

In another form of the present disclosure, a mold system is for formingmultilevel blocks is disclosed that comprises a number of multilevelmold box inserts each for forming a multilevel block, a mold box frameadapted for receiving therein the number of multilevel mold box inserts,a number of multilevel plunger assemblies for each of the multilevelmold box inserts, and a press head plate adapted for receiving thereoneach of the multilevel plunger assemblies.

In yet another form of the present disclosure, a mold system for formingmultilevel blocks is disclosed that comprises a first multilevel moldbox insert for forming a multilevel block of a first configuration, asecond multilevel mold box insert for forming a multilevel block of asecond configuration, a mold box frame adapted for receiving therein themultilevel mold box inserts, a first multilevel plunger assemblyassociated with the first multilevel mold box insert, a secondmultilevel plunger assembly associated with the second multilevel moldbox insert, and a press head plate adapted for receiving thereon themultilevel plunger assemblies.

The present disclosure also provides a mold system for formingmultilevel blocks that is easy to use to manufacture various shapedmultilevel blocks that may be used to construct both residential andcommercial landscaping projects.

The present disclosure provides a mold system for manufacturingmultilevel blocks wherein each of the blocks are strong, not prone tobreaking, and can withstand lawn mowing equipment being moved over theblocks.

The present disclosure provides a mold system for manufacturingmultilevel blocks with each of the blocks being small, lightweight, easyto handle, and are prone to not shift or tilt once installed.

The present disclosure also provides a mold system for manufacturingmultilevel blocks that can be installed in numerous layouts, designs,and patterns.

The present disclosure provides a mold system for manufacturingmultilevel blocks in which the blocks can be manufactured by use of amold having a raised area and a mold screed or strike-off plate used inconjunction with the mold having a raised area to form the variousblocks.

The present disclosure also provides a mold system for manufacturingmultilevel blocks in which the blocks are locked together to controlseparating and to allow a mower to ride on or over the blocks to controlmovement of the blocks.

The present disclosure further provides a mold system for formingmultilevel blocks in which various different shaped multilevel blocksmay be formed at the same time.

These and other advantages of the present disclosure will becomeapparent after considering the following detailed specification inconjunction with the accompanying drawings, wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a mold system for forming multilevelblocks constructed according to the present disclosure;

FIG. 2 is a perspective view of a mold box frame including mold boxinserts constructed according to the present disclosure;

FIG. 3 is a perspective view of a mold box insert constructed accordingto the present disclosure that is used to form a multilevel straightblock;

FIG. 4 is perspective view of a mold box insert constructed according tothe present disclosure that is used to form a multilevel tree ring blockor an outside radius block;

FIG. 5 is a bottom view of the mold box insert shown in FIG. 4;

FIG. 6 is a perspective view of a mold box insert constructed accordingto the present disclosure that is used to form a multilevel inside arcor radius block;

FIG. 7 is a top view of a plunger head plate constructed according tothe present disclosure;

FIG. 8 is a perspective view of a plunger assembly shown partially inphantom that is used to form a multilevel straight block constructedaccording to the present disclosure;

FIG. 9 is a perspective view of a plunger assembly shown partially inphantom that is used to form a multilevel tree ring block constructedaccording to the present disclosure;

FIG. 10 is a perspective view of a plunger assembly shown partially inphantom that is used to form a multilevel inside arc or radius blockconstructed according to the present disclosure;

FIG. 11 is a perspective view of a straight block of the landscapeedging system constructed according to the present mold system forforming multilevel blocks;

FIG. 12 is a top view of the straight block of the landscape edgingsystem constructed according to the present mold system for formingmultilevel blocks;

FIG. 13 is a perspective view of an outside radius or tree ring block ofthe landscape edging system constructed according to the present moldsystem for forming multilevel blocks;

FIG. 14 is a top view of the tree ring block of the landscape edgingsystem constructed according to the present mold system for formingmultilevel blocks;

FIG. 15 is a perspective view of an inside radius block of the landscapeedging system constructed according to the present mold system forforming multilevel blocks;

FIG. 16 is a top view of an inside radius block of the landscape edgingsystem constructed according to the present mold system for formingmultilevel blocks;

FIG. 17 is an end view of the straight block constructed according tothe present mold system for forming multilevel blocks being installed inthe ground in a landscaped area;

FIG. 18 is a cross-sectional view of the present mold system in aforming position forming a number of multilevel blocks;

FIG. 19 is a cross-sectional view of the present mold system in astripping position forming a number of multilevel blocks;

FIG. 20 is a cross-sectional view of the present mold system in afurther stripping position forming a number of multilevel blocks;

FIG. 21 is a front view of a screed plate used to manufacture blocks ofthe present mold system for forming multilevel blocks;

FIG. 22 is a perspective view of a tree ring being formed by use ofnumerous tree ring blocks constructed according to the present moldsystem for forming multilevel blocks;

FIG. 23 is a cross-sectional view of another embodiment of the moldsystem of the present disclosure forming a multilevel block; and

FIG. 24 is a cross-sectional view of the mold system of FIG. 23 in whichthe mold system has been stripped away from the multilevel block.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring now to the drawings, wherein like numbers refer to like items,number 10 identifies a mold system for forming multilevel blocks in amachine, such as a block or paver machine, constructed according to thepresent disclosure. With reference now to FIG. 1, the mold system 10comprises a mold box assembly 12 having a mold box frame 14 forreceiving a number of multilevel mold box inserts 16, 18, 20, 22, and24. The multilevel mold box inserts 16, 18, 20, 22, and 24 are sized andshaped to form multilevel blocks (not shown) of various configurationsas will be discussed further herein. In particular, the mold box inserts16 and 18 may be used to form straight blocks, the mold box inserts 20and 22 may be used to form tree ring blocks or outside radius blocks,and the mold box insert 24 may be used to form an outside curved orradius block. The mold system 10 also comprises a press head plate 28that has attached thereto a number of multilevel plunger assemblies 30,32, 34, 36, and 38. The press head plate 28 is also adapted to beattached to a block or paver machine (not shown). The multilevel plungerassemblies 30, 32, 34, 36, and 38 are sized and shaped to assist informing multilevel blocks being formed in the mold box inserts 16, 18,20, 22, and 24. For example, the plunger assemblies 30 and 32 are usedto form straight blocks, the plunger assemblies 34 and 36 are used toform tree ring blocks, and the plunger assemblies 38 is used to form aninside curved block. The mold box inserts 16, 18, 20, 22, and 24 areinterchangeable on the mold box frame 14. In particular, the mold boxframe 14 may have all of the mold box inserts being the mold box insert16. In this case, there will be ten straight blocks formed. The othermold box inserts 20, 22, and 24 may be placed in or on the mold boxframe 14, as required to form or manufacture other blocks. Further, theplunger assemblies 30, 32, 34, 36, and 38 are interchangeable as well.By way of example, if the mold box frame 14 is fitted with five of themold box inserts 16 then the press head plate 28 will be fitted with tenof the plunger assemblies 30 in order to form the ten straights blocks.Although various numbers of mold box inserts and plunger assemblies areshown, it is contemplated that a different number of mold box insertsand plunger assemblies may be used by different types of block machines.Further, although not shown, it is to be understood that in a block orpaver machine a production board or a steel plate will be placed underthe mold box frame 14 by the machine to facilitate forming blocks in themold system 10.

With reference now to FIG. 2, a perspective view of the mold box frame14 is shown having the mold box inserts 16, 18, 20, 22, and 24positioned therein or thereon. The mold box inserts 16, 18, 20, 22, and24 may be positioned in the mold box frame 14 in any manner orconfiguration. For example, the mold box insert 22 may be removed andanother mold box insert 16 may be positioned in its place. In thismanner, six straight blocks may be formed using the mold system 10. Itis also possible that the mold box insert 24 may be removed from themold box frame 14 and only straight blocks and tree ring blocks may beformed in this particular arrangement. By further way of example, themold box insert 18 may be reversed in orientation so that low sides ofthe blocks are formed back to back or both the mold box inserts 16 and18 may be reversed so that high sides of the blocks are formed back toback. The mold box frame 14 is generally rectangular in shape. Forpurposes of example only, some possible standard dimensions for the moldbox frame 14 are 26 inches wide by 18½ inches deep or 30 inches wide by39 inches deep.

FIG. 3 is a perspective view of the mold box insert 16 that is used toform a straight multilevel straight block. The mold box insert 16comprises a back panel 40, a right side panel 42, a central panel 44, aleft side panel 46, a front panel 48, and an upper central panel 50. Thepanels 40, 42, 44, 46, 48, and 50 may be secured to each other by use onflathead countersunk bolts 52, screws, or other suitable securingelements. The right side panel 42 has a tab portion 54 that is used tohold the mold box insert 16 within the mold box assembly 12 of the moldbox frame 14. In particular, the mold box frame 14 may have rails 26(FIGS. 1 and 2) that are used to capture the tab portion 54. Althoughnot shown in this view, there is another tab on the left side panel 46.The back panel 40 has a pair of tabs 56 and 58 that extend out from theback panel 40 and are used to be retained by the rails 26. The frontpanel 48 also has a tab 60 that is retained by the rails 26. Althoughnot shown, there is another tab at the other end of the front panel 48.The right side panel 42 has a lower edge 62 and an upper edge 64. Theedges 62 and 64 are used in part to form the multilevel block. As can beappreciated, any concrete placed in the openings of the mold box insert16 will be formed into a pair of straight multilevel blocks. Further,the panels 40, 42, 44, 46, 48, and 50 may be constructed of steel plateor other suitable material. It is also possible that the mold box insert16 may be formed of a unitary construction instead of component parts.It is also to be noted that the top openings of the insert 16 arebeveled to facilitate alignment of the plunger assembly 30 during themanufacturing process.

FIG. 4 is a perspective view of mold box insert 20 that is used to formthree multilevel tree ring blocks. The mold box insert 20 comprises aback panel 70, a right side panel 72, a first central panel 74, a secondcentral panel 76, a left side panel 78, a front panel 80, and a uppercentral panel 82. The panels 70, 72, 74, 76, 78, 80, and 82 may besecured to each other by use of flathead countersunk bolts 84, screws,or other suitable securing elements. The right side panel 72 has a tabportion 86 that is used to hold the mold box insert 20 within the moldbox assembly 12 of the mold box frame 14 by being captured by the rail26. Although not shown in this view, there is another tab on the leftside panel 78. The back panel 70 has a tab 88 that extends out from theback panel 70 which is used to be retained by the rail 26 of the moldbox frame 14. The other side of the back panel 70 also has a tab. Thefront panel 80 has a pair of tabs 90 and 92 that are captured by therails 26 of the mold box frame 14. The right side panel 72 has a loweredge 94 and an upper edge 96. The edges 62 and 64 are used in part toform the multilevel block. The first central panel 74 and the secondcentral panel 78 are used to separate the blocks and to form threeseparate multilevel tree ring blocks. Also, the panels 70, 72, 74, 76,78, 80, and 82 may be constructed of steel plate or any other suitablematerial. Also, the insert 20 may be a unitary construction. Further,the top openings of the insert 20 are beveled to assist the plungerassembly 34 to be guided into the insert 20 during the manufacturingprocess.

Referring now to FIG. 5, a bottom view of the mold box insert 20 isdepicted. The mold box insert 20 is shown to comprise the back panel 70,the right side panel 72, the first central panel 74, the second centralpanel 76, the left side panel 78, and the front panel 80. The panels 70,72, 74, 76, 78, and 80 are shown held together by use of the bolts 84. Atab 98 is shown extending from the back panel 70 along the right sidepanel 72. Also, a tab 100, similar to the tab 86, is positioned alongthe left side panel 78. With use of the mold box insert 20, threemultilevel tree ring blocks may be formed. Further, the openings in thebottom view of the mold box insert 20 are not beveled. This is due tothe plunger assembly 34 never going fully through the insert 20 duringthe manufacturing process.

FIG. 6 is a perspective view of the mold box insert 24 that is used toform a multilevel inside radius or curved block. The mold box insert 24comprises a back panel 102, a right side panel 104, a first centralpanel 106, a second central panel 108, a left side panel 110, a frontpanel 112, and an upper central panel 114. The panels 102, 104, 106,108, 110, 112, and 114 may be secured to each other by use of flatheadcountersunk bolts 116, screws, or other suitable securing elements. Theright side panel 104 has a tab portion 118 that is used to hold the moldbox insert 24 within the mold box frame 14 of the mold box assembly 12by being captured by the rail 26. Although not shown in this view, thereis another tab on the left side panel 110. The back panel 102 has a tab120 that extends out from the back panel 102 which is used to beretained by the rail 26. The other side of the back panel 102 also has atab. The front panel 112 has a pair of tabs 122 and 124 that arecaptured by the rails 26. The right side panel 104 has a lower edge 126and an upper edge 128. The edges 126 and 128 are used to form themultilevel block. The first central panel 106 has a lower edge 130 andan upper edge 132. The second central panel 108 also has a lower edge134 and an upper edge 136. The left side panel 110 is also formed tohave a lower edge 138 and an upper edge 140. The first central panel 106and the second central panel 108 are used to separate the blocks and toform three separate multilevel inside arc blocks. As indicated above,the panels 102, 104, 106, 108, 110, 112, and 114 may be constructed ofsteel plate or any other suitable material. Further, instead ofcomponent parts, the mold box insert 24 may be a unitary construction.

FIG. 7 is a top view of the press head plate 28. The press head plate 28is generally rectangular in shape and has a plurality of mounting holes144 formed therein. The mounting holes 144 are used to mount the plungerassemblies 30, 32, 34, 36, and 38 to the press head plate 28 by use ofbolts, screws, or other suitable securing or mounting devices. With thisparticular press head plate 28, up to five plunger assemblies may bemounted or attached thereto. However, it is possible that the press headplate 28 may be constructed to accommodate more plunger assemblies byuse of more mounting holes 144 formed therein. It is also contemplatedthat the press head plate 28 may have fewer plunger assemblies mountedthereto by use of fewer mounting holes 144.

Referring now to FIG. 8, the plunger assembly 30 is illustrated. Theplunger assembly 30 comprises a top mounting plate 150 have mountingholes 152 that correspond to the mounting holes 144 of the press headplate 28. Aligning the holes 144 and 152 will allow the plunger assembly30 to be mounted to the press head plate 28 by use of any suitablemounting device such as bolts or screws. The top mounting plate 150 hasa first front pair of tubes 154 and 156 connected thereto and a firstfront press plate mounting plate 158 connected to the tubes 154 and 156with a first front press plate 160 connected to the first front pressplate mounting plate 158. The first front press plate 160 is adapted tobe pressed down on material in the mold box insert 16 to facilitateforming of a block. The top mounting plate 150 has a second front pairof tubes 162 and 164 connected thereto and a second front press platemounting plate 166 connected to the tubes 162 and 164. A second frontpress plate 168 is connected to the second front press plate mountingplate 166. The second front press plate 168 is used to press down onmaterial in the mold box insert 16. A first rear pair of tubes 170 and172 are connected to the top mounting plate 150. The first rear pair oftubes 170 and 172 have a first rear press plate mounting plate 174connected thereto. Attached to the first rear press plate mounting plate174 is a first rear press plate 176. The top mounting plate 150 also hasa second rear pair of tubes 178 and 180 connected thereto. The secondrear pair of tubes 178 and 180 have a second rear press plate mountingplate 182 connected to the tubes 178 and 180. A second rear press plate184 is attached to the second rear press plate mounting plate 182. Ascan be appreciated, the press plates 160, 168, 176, and 184 are used tobe pressed down on material in the mold box insert 16 to assist informing a straight multilevel block. Also, the press plates 160, 168,176, and 184 are shaped in the same shape as openings in the mold boxinsert 16. It is also possible that the tubes 154, 156, 162, 164, 170,172, 178, and 180 may be welded directly to the press head plate 28.

FIG. 9 shows the plunger assembly 34. The plunger assembly 34 comprisesa top mounting plate 200 have mounting holes 202 that correspond to themounting holes 144 of the press head plate 28. Aligning the holes 144and 202 will allow the plunger assembly 34 to be mounted to the presshead plate 28 by use of any suitable mounting device such as bolts orscrews. The top mounting plate 200 has a first front tube 204 connectedthereto, a first front press plate mounting plate 206, and a first frontpress plate 208 connected to the first front press plate mounting plate206. The first front press plate 208 is adapted to be pressed down onmaterial in the mold box insert 20 to facilitate forming of a block. Thetop mounting plate 200 has a second front tube 210 connected thereto anda second front press plate mounting plate 212 connected to the tube 210.A second front press plate 214 is connected to the second front pressplate mounting plate 212. A third front tube 216 is connected to theplate 200. The third front tube 216 also has a third front press platemounting plate 218 connected thereto and a third front press plate 220connected to the plate 218. A first rear tube 222 is connected to thetop mounting plate 200. The first rear tube 222 has a first rear pressplate mounting plate 224 connected thereto and a first rear press plate226 attached to the plate 224. The top mounting plate 200 also has asecond rear tube 228 connected thereto. The second rear tube 228 hasconnected thereto a second rear press plate mounting plate 230 andattached to the plate 230 is a second rear press plate 232. A third reartube 234 is connected to the plate 200. The third rear tube 234 has athird rear press plate mounting plate 236 and a third rear press plate238. As can be appreciated, the press plates 208, 214, 220, 226, 232,and 238 are used to be pressed down on material in the mold box insert20 to assist in forming a tree ring or outside radius shaped multilevelblock. Also, the press plate 208, 214, 220, 226, 232, and 238 are shapedin the same shape as the mold box insert 20. With use of the plungerassembly 34, three tree ring shaped multilevel blocks may be formed. Itis also possible that the tubes 204, 210, 216, 222, 228, and 234 may bewelded directly to the press head plate 28.

With reference now to FIG. 10, a perspective view of the plungerassembly 38 that is used to manufacture multilevel inside radius blocksis illustrated. The plunger assembly 38 has a top mounting plate 250have mounting holes 252 that correspond to the mounting holes 144 of thepress head plate 28. The holes 252 are aligned with the holes 144 toconnect the plates 28 and 250 together. The plate 250 has a first fronttube 254 connected thereto, a first front press plate mounting plate256, and a first front press plate 258 connected to the first frontpress plate mounting plate 256. The first front press plate 258 isadapted to be pressed down on material the mold box insert 24 tofacilitate forming of a block. The top mounting plate 250 has a secondfront tube 260 connected thereto and a second front press plate mountingplate 262 connected to the tube 260. A second front press plate 264 isconnected to the second front press plate mounting plate 262. A thirdfront tube 266 is connected to the plate 250. The third front tube 266also has a third front press plate mounting plate 268 connected theretoand a third front press plate 270 connected to the plate 268. A firstrear tube 272 is connected to the top mounting plate 250. The first reartube 272 has a first rear press plate mounting plate 274 connectedthereto and a first rear press plate 276 attached to the plate 274. Thetop mounting plate 250 also has a second rear tube 278 connectedthereto. The second rear tube 278 has connected thereto a second rearpress plate mounting plate 280 and attached to the plate 280 is a secondrear press plate 282. A third rear tube 284 is connected to the plate250. The third rear tube 284 has a third rear press plate mounting plate286 and a third rear press plate 288. As can be appreciated, the pressplates 258, 264, 270, 276, 282, and 288 are used to be pressed down onmaterial in the mold box insert 24 to assist in forming an inside arcshaped multilevel block. Also, the press plates 258, 264, 270, 276, 282,and 288 are shaped in the same shape as the mold box 38. With the use ofthe plunger assembly 38 three inside radius shaped multilevel blocks maybe formed. It is also possible that the tubes 254, 260, 266, 272, 278,and 284 may be welded directly to the press head plate 28.

As discussed previously, although two tiers have been shown, it ispossible and contemplated that three or more tiers may be formed by useof the plunger assemblies 30, 32, 34, 36, and 38 by adding more tubes,press plate mounting plates, and press plates as the case may require.For example, for a block having three tiers or levels, three additionaltubes will be connected to the top mounting plate 250. The tubes willeach then have connected to an opposite end thereof a press platemounting plate and a press plate. In this manner, various multilevelshaped blocks may be formed and manufactured.

FIG. 11 is a perspective view of a straight block 330 which isconstructed using the mold system for forming multilevel blocks 10 ofthe present disclosure. In particular, the mold press box insert 16along with the plunger assembly 30 may be used to form the straightblock 330. The straight block 330 comprises a back face 332 and a bottomface 334, an elevated top portion 336, a lower top portion 338, anelevated front face 340 between the elevated top portion 336 and thelower top portion 338, a lower side front face 342, a right elevatedside face 344, a right lower side face 346 having a tongue portion 348extending out from the right lower side face 346, a left elevated sideface 350, a left lower side face 352 having a groove portion 354 formedin the left lower side face 352. The tongue portion 348 extends betweenthe bottom face 334 and the lower top portion 338. The lower top portion338 serves as the edge 322 that lawn mowing equipment may ride upon whencutting grass. The faces 334, 340, 342, 344, 346, 350, 352 and the topportion 336 and the lower top portion 338 are generally planar andrectangular in shape.

Referring to FIG. 12, a top view of the straight block 330 is depicted.The straight block 330 is shown comprising the back face 332, theelevated top portion 336, the lower top portion 338, and the elevatedfront face 340 between the elevated top portion 336 and the lower topportion 338. The block 330 further comprises the lower side front face342, the right elevated side face 344, the right lower side face 346having the tongue portion 348 extending out from the right lower sideface 346, and the left elevated side face 350. The left lower side face352 has the groove portion 354 formed therein and also is formed in thelower top portion 338. The tongue portion 348 extends between the bottomface 334, which is not shown in this particular view, and the lower topportion 338. The lower top portion 338 serves as the platform or edge322 upon which lawn mowing equipment may ride upon when cutting grass.

An eased, beveled, or rounded edge 360 is formed between back face 332and the elevated top portion 336. Another eased or rounded edge 362 isformed between the elevated top portion 336 and the elevated front face340. Between the elevated front face 340 and the lower top portion 338is formed a rounded edge 364. Also, another eased or rounded edge 366 isformed between the lower top portion 338 and the lower side front face342. The edges 360, 362, 364, and 366 are eased, beveled, or rounded toprevent the straight block 330 from being broken or chipped duringmanufacturing, transportation, storage, installation, or handling. Also,the tongue portion 348 may have rounded edges 368 and the groove portion354 may have rounded edges 370. The rounded edges 368 and 370 preventcracks initiating during the manufacturing process. As can beappreciated, when a line of straight blocks 330 are placed side by side,the tongue portion 348 of one of the blocks 330 may be inserted into thegroove portion 354 of the adjacent block 330. In this manner, the blocks330 may be joined or mated together.

For purposes of example only, some possible standard dimensions for thestraight block 330 are as follows. The straight block 330 may be fourinches tall at the back face 332, two inches tall at the lower sidefront face 342, six inches deep along the bottom face 334, and twelveinches wide along both the back face 332 and the lower side front face342. The tongue portion 348 may extend out 7/16 inches, have a width of⅞ inches, and have a height of two inches. The groove portion 354 mayhave a depth of 1/2 inches, a width of one inch, and a height of twoinches. In this manner, the tongue portion 348 will fit within thegroove portion 354. Another reason that the tongue portion 348 has awidth of ⅞ inches and the groove portion 354 has a width of one inch isdue to the manufacturing process. When manufacturing or molding theblock 330, as will be described in more detail herein, a mold in whichthe block 330 is formed will wear down over time. In order to allow amold to be used for as long as possible, these tolerances are built into the block 330. It should be apparent that the tongue portion 348 andthe groove portion 354 are positioned along the right lower side face346 and the left lower side face 352, respectively. In thisconfiguration, the tongue portion 348 and the groove portion 354 are notpart of either the right elevated side face 344 or the left elevatedside face 350. Further, by having the tongue portion 348 and the grooveportion 354 positioned along the side faces 346 and 352, respectively,the connection between a pair of blocks 330 is strengthen and this helpsprevent movement of the blocks 330 when lawn mowing or cutting equipmentis placed on the lower top portion 338. Other reasons for positioningthe tongue portion 348 on the side face 346 and the groove portion 354on the side face 352 are that such a construction is easier tomanufacture, it does not detract from the appearance of the block 330,and it prevents separation of the blocks 330 on an uneven surface suchas a slight inclined or uphill surface.

FIG. 13 illustrates a perspective view of a tree ring or outside radiusblock 400 constructed according to the present disclosure. The moldpress box insert 20 and the plunger assembly 34 may be used to form thetree ring block 400. The tree ring block 400 comprises a back face 402that is configured to be placed against a raised area and a bottom face404 for placement in the ground, an elevated top portion 406, a lowertop portion 408, an elevated front face 410 positioned between theelevated top portion 406 and the lower top portion 408, a lower sidefront face 412, a left elevated side face 414, a left lower side face416 having a groove portion 418 formed in the left lower side face 416.The lower top portion 408 serves as an edge that lawn mowing equipmentmay ride upon when cutting grass.

With reference now to FIG. 14, a top perspective view of the tree ringblock 400 is illustrated. The tree ring block 400 further comprises aright elevated side face 420 and a right lower side face 422 having agroove portion 424 formed in the right lower side face 422. The grooveportion 424 extends between the bottom face 404, which is not shown inthis particular view, and the lower top portion 408. The tree ring block400 is also shown to comprise the back face 402, the elevated topportion 406, the lower top portion 408, the elevated front face 410, andthe lower side front face 412. The left lower side face 416 has thetongue portion 418 extending out from the left lower side face 416. Thetongue portion 418 is adapted to be placed or positioned in the grooveportion 424 of an adjoining block 330 or 400.

An eased, beveled, or rounded edge 426 is formed between back face 402and the elevated top portion 406. Another eased or rounded edge 428 isformed between the elevated top portion 406 and the elevated front face410. Between the elevated front face 410 and the lower top portion 408is formed a rounded edge 430. Also, another eased or rounded edge 432 isformed between the lower top portion 408 and the lower side front face412. The edges 426, 428, 430, and 432 are eased, beveled, or rounded toprevent the block 400 from being broken or chipped during manufacturing,transportation, storage, installation, or handling. Also, the tongueportion 418 may have rounded edges 434 and the groove portion 424 mayhave rounded edges 436. The rounded edges 434 and 436 prevent cracksfrom initiating during the manufacturing process. As can be appreciated,when a outside radius circular border is required, the outside radiusblock 400 may be used. Each of the blocks 400 is arcuate in shape andhas a radius of 22.5°. A total of sixteen of the blocks 400 may be usedto form a complete circle for a ring around a tree. Also, the tongueportion 348 of the straight block 330 may be inserted into the grooveportion 424 of the block 400 to form an outside radius border.

Again, for purposes of example only, some possible standard dimensionsfor the outside radius block 400 are a height of four inches at the backface 402, two inches tall at the lower side front face 412, and sixinches deep along the bottom face 404. The tongue portion 418 may extendout 7/16 inches, have a width of ⅞ inches, and have a height of twoinches. The groove portion 424 may have a depth of ½ inches, a width ofone inch, and a height of two inches. In this manner, the tongue portion418 will fit within the groove portion 424. It should be apparent thatthe tongue portion 418 and the groove portion 424 are positioned alongthe left lower side face 416 and the right lower side face 422,respectively.

Referring now to FIG. 15, an inside radius block 450 is shown that maybe constructed by use of the mold box insert 24 and the plunger assembly28 of the present mold system 10. The inside radius block 450 comprisesa back face 452 that is configured to be placed against a raised areaand a bottom face 454 for placement in the ground, an elevated topportion 456, a lower top portion 458, an elevated front face 460 betweenthe elevated top portion 456 and the lower top portion 458, a lower sidefront face 462, a left elevated side face 464, a left lower side face466 having a groove portion 468 formed in the left lower side face 466.The lower top portion 458 serves as an edge that lawn mowing equipmentmay travel or ride upon when cutting the grass.

FIG. 16 illustrates a top perspective view of the inside radius block450. The inside radius block 450 further comprises a right elevated sideface 470 and a right lower side face 472 having a tongue portion 474extending out from the right lower side face 472. The tongue portion 474extends between the bottom face 454, which is not shown in thisparticular view, and the lower top portion 458. The inside radius block450 is also shown to comprise the back face 452, the elevated topportion 456, the lower top portion 458, the elevated front face 460, andthe lower side front face 462. The left lower side face 466 has thegroove portion 468 formed and the groove portion 468 is adapted forreceiving a tongue portion 474 of an adjoining block 330 or 450. Thegroove portion 468 is formed in the left lower side face 466, the lowertop portion 458, and the bottom face 454. As can be appreciated, theinside radius block 450 is used to form a border when an inside radiusis required. Further, each of the blocks 450 is arcuate in configurationand has a radius of 22.5°. Due to this construction, a total of sixteenof the blocks 450 may be used to form a complete circular border.

With reference now to both FIGS. 15 and 16, an eased, beveled, orrounded edge 476 is formed between back face 452 and the elevated topportion 456. Another eased or rounded edge 478 is formed between theelevated top portion 456 and the elevated front face 460. Between theelevated front face 460 and the lower top portion 458 is formed arounded edge 480. Also, another eased or rounded edge 482 is formedbetween the lower top portion 458 and the lower side front face 462. Theedges 476, 478, 480, and 482 are eased, beveled, or rounded to preventthe block 450 from being broken or chipped during manufacturing,transportation, storage, installation, or handling. Also, the tongueportion 474 may have rounded edges 484 and the groove portion 468 mayhave rounded edges 486. The rounded edges 484 and 486 are used toprevent cracks from initiating during the manufacturing process.

As has been referenced previously, the block 450 may be formed in sizesthat are standardized. Some possible standard dimensions for the insideradius block 450 are a height of four inches at the back face 452, twoinches tall at the lower side front face 462, and six inches deep alongthe bottom face 454. The tongue portion 474 may extend out 7/16 inches,have a width of ⅞ inches, and have a height of two inches. The grooveportion 468 may have a depth of 1/2 inches, a width of one inch, and aheight of two inches. In this manner, the tongue portion 474 will fitwithin the groove portion 468. It should be apparent that the tongueportion 474 and the groove portion 468 are positioned along the rightlower side face 472 and the left lower side face 466, respectively. Inthis configuration, the tongue portion 474 and the groove portion 468are not part of either the right elevated side face 470 or the leftelevated side face 464. It should be apparent that the blocks 330, 400,and 450 have the same sized tongues and grooves that allow the blocks330, 400, and 450 to be placed in any sequence or configuration.

As depicted in FIG. 17, a straight block 330 is shown being installed ina dugout or trench area 500 of soil 502 in the ground 504. The trencharea 500 may be excavated which approximates the size of the block 330and the desired border configuration. The trench area 500 is dug deepenough so that the lower top portion 338 of the straight block 330 islevel with a ground level 506 of the ground 504. Although not shown, itis also possible to provide a leveling base, such as crushed rock, onthe soil 502 to place the bottom face 334 of the block 330. The groundlevel 506 has grass 508 on a side in which the top portion 338 ispresented to allow a lawn mower (not shown) to ride or travel over whencutting the grass 508. The back side 332 of the block 330 is shownabutting up against mulch 510 that is in a landscaped area 512. In thismanner, the block 330 is able to keep the mulch 510 within thelandscaped area 512 and also to provide the lower top portion 338 as asurface upon which the lawn mower may move or travel. The lower topportion 338 allows the grass 508 to be cut without having to go back andtrim the area between the grass 508 and the mulch 510 if the landscapeedging block 330 had not been installed. Again, since the lower topportion 338 is level or flush with the ground level 506, a lawn mowermay ride continuously along the lower top portion 338 of the block 330when cutting the grass 508. Once the block 330 is installed, anotherblock 330 may have its groove portion 354 (not shown) placed over thetongue portion 348 to lock the two blocks 330 together. Further, due tothe standardization of the tongue portions and groove portions of theblocks 330, 400, and 450 described herein, any of the blocks may beconnected together to form any shape and sized border configuration.Also, although the block 330 is depicted as being installed in thetrench area 500, it is also possible and contemplated to install any ofthe other blocks 400 and 450 in the same manner.

FIG. 18 shows a cross-sectional view of the mold system 10 in positionforming the blocks 330, 400, and 450. The mold box frame 14 has the moldbox inserts 16, 18, 20, 22, and 24 placed thereon or therein and hasbeen moved into position in a machine (not shown) for automatingmanufacturing of blocks. Material, such as concrete, has been droppedinto the mold boxes 16 and a screed bar (not shown) has been moved overthe material to remove excess material. The plunger assemblies 30, 32,34, 36, and 38 have been moved into position to compress the material inthe mold box inserts 16, 18, 20, 22, and 24. It is also known that themachine may vibrate the material at the same time the plunger assemblies30, 32, 34, 26, and 38 are compressing the material. In this manner, theblocks 330, 400, and 450 are formed. In this particular configuration,four of the straight blocks 330, six of the tree ring blocks 400, andthree of the inside radius blocks 450 may be formed at a time. It shouldbe noticed that the thickness of the press plate 160 of the plungerassembly 30 is thicker than the press plate 176. The thicker press plate160 helps during the stripping cycle to keep the flat surface 338 of theblock 330 (FIGS. 11 and 12) in place. Also, the top of the thicker pressplate 160 never moves below the bottom of the mold box insert 16 torelease the plunger assembly 30 from the material being compressed. Thepress plate 208 is also thicker than the press plate 226 of the plungerassembly 34. Further, the press plate 276 is thicker than the pressplate 258 of the plunger assembly 38.

Referencing now FIG. 19, a cross-sectional view of the mold system 10 inwhich the mold box frame 14 and the mold box inserts 16, 18, 20, 22, and24 have been moved upwardly to strip the mold system 10 away from theblocks 330, 400, and 450. The plunger assemblies 30, 32, 34, 36, and 38are still in contact with the blocks 330, 400, and 450 in thisparticular step of the process. The formed blocks 330, 400, and 450 areleft on a board 520 for further processing. In this manner, the moldsystem 10 is able to form the blocks 330, 400, and 450. Once the formingprocess is complete, the blocks 330, 400, and 450 sitting on the board520 may be sent down an assembly line or removed from the machine forcuring. For example, the board 520 holding the blocks 330, 400, and 450may be moved to a curing room for a period of time.

FIG. 20 illustrates a further step in the manufacturing process in whichthe plunger assemblies 30, 32, 34, 36, and 38 have been moved upwardlyto completely strip the mold system 10 away from the blocks 330, 400,and 450. The formed blocks 330, 400, and 450 are left positioned on theboard 520 for further processing, as previously described. As furtherdepicted in this drawing and which has been previously indicated, thethicker press plate 160 never moves below the bottom of the mold boxinsert 16 when the plunger assembly 30 is released from the materialbeing compressed. The press plates 208 and 226 do not move below thebottom of the mold box insert 20 and the press plates 258 and 276 alsodo not move below the bottom of the mold box insert 24.

As can be appreciated, the blocks 330, 400, and 450 of the presentdisclosure are formed in suitable mold box inserts 16, 20, 24,respectively. Generally, the process entails molding the blocks 330,400, and 450 by using a mixture of cement, rock, sand, water, and othermaterials. Once the mixture is inserted into each of the openings of themold box inserts 16, 20, and 24 of the mold box assembly 12, a screed orstrike-off plate is passed over the mold box assembly 12 to remove anyexcess mixture. The blocks 330, 400, and 450 are fabricated bycompressing and vibrating the mixture in the mold box assembly 12 by theapplication of pressure to the mixture by use of a block machine orsimilar machine. The press head plate 28 having various plungerassemblies, such as the multilevel plunger assemblies 30, 34, and 38,are used to apply pressure to the mold box assembly 12. As previouslydescribed, the multilevel plunger assemblies include press head mountingplaces and press plates. The press plates of the multilevel plungerassemblies may have a pattern, such as a stone pattern, to add characterto the visible surfaces of the blocks 330, 400, and 450. By way ofexample only, the elevated top portion 336 and the lower top portion 338of the block 330 are visible surfaces which may have a pattern formedtherein. For example, the press plate may have a cobblestone patternthat may be transferred to the visible surfaces 336 and 338 of the block330. Also, the press plate may be heated to facilitate release of thepress plate from the blocks 330, 400, and 450. Once the blocks 330, 400,and 450 are formed they may be cured through any method known in theart. For example, curing may take the form of air curing for a number ofdays or steam curing, but normally one day is allowed or needed foradequate cure.

Many combinations of concrete mixtures may be employed in manufacturingthe blocks 330, 400, and 450. Some considerations in determining theparticular concrete mixtures include compression strength requirements,density, and adsorption. Further, the costs of the materials, such assand, gravel, cement, pigment additives, and rock have an impact on themixture to be used. For example, gravel may be cheaper than river rockin some areas of the country and the blocks 330, 400, and 450 may beformed of a mixture having more gravel than rock due to the differencein cost. The blocks 330, 400, and 450 may be constructed with coloredpigments to form different colored blocks. In particular and by way ofexample only, the block 330 may be formed from one color, the block 400may be constructed of a second or different color, and the block 450 maybe constructed of a third color. In this manner the blocks 330, 400, and450 may have contrasting colors that add to texture, appearance, ordetail to any landscaping project or structure. It should be recognizedthat the blocks 330, 400, and 450 of the present disclosure may beconstructed of various materials that are available. Preferably, theblocks 330, 400, and 450 will be of relatively lightweight so that theblocks 330, 400, and 450 can be easily manufactured, stored,transported, and installed. Also, any multilevel block formed by themold system 10 may be of any size or configuration by use of a suitablesized and configured mold box and plunger assembly.

FIG. 21 illustrates a screed or strike-off plate 550 which is configuredto remove any excess concrete mixture which is used to form the blocks330, 400, or 450. The plate 550 has cut out areas 552 along a lower end554 which allow the plate 550 to move over each elevated portion, suchas the upper edge 64 of the mold box insert 16, of the mold box assembly12. In this manner, excess concrete mixture is removed from both theelevated top portion 336 and the lower top portion 338 when forming theblock 330 in the mold box assembly 12. The plate 550 also has cut outareas 556 along an upper end 558. Brushes (not shown) may be placedalong the cut out areas 556 and the upper end 558 to brush off anyexcess mixture and to clean off the press plates. It is also possiblethat different shaped screed plates 550 may be required or may be used.For example, if the mold box inserts 16 are orientated in the mold boxassembly 12 back to back, then a different screed plate 550 will have tobe used in which the different screed plate 550 will have wider openingsor cut out areas 552 and 556 and wider brushes.

FIG. 22 shows a tree ring 600 that may be constructed using the treering blocks 400 that can be used to form a border around a tree (notshown). In particular, since each of the blocks 400 has a 22.5° radiussixteen of the blocks 400 are required to form a complete circularborder. The blocks 400 are connected together by use of the grooveportion 418 and the tongue portion 424. Each of the blocks 400 has theelevated top portion 406 and the lower top portion 408. The lower topportion 408 presents a platform or surface upon which wheels of lawncutting equipment may ride or travel upon when cutting grass. As can beappreciated, grass that grows along or adjacent to the blocks 400 is cutto the same height as grass that grows in the lawn. The blocks 400 alsokeep or hold in any mulch, dirt, or rocks inside the tree ring 600.Further, other blocks, such as the blocks 330 and 450 may be used toconstruct a border having any configuration around a tree, a plantingbed, or area.

Referring now to FIG. 23, another embodiment of a mold system 620 forforming a three tiered multilevel block 622 is shown. The mold system620 comprises a mold box insert 624 that is adapted to be placed in amold box frame (not shown), a plunger assembly 626, and a press headplate 628. The plunger assembly 626 includes a first tube 630 having afirst press plate 632, a second tube 634 having a second press plate636, and a third tube 638 having a third press plate 640. In thisparticular embodiment the tubes 630, 634, and 638 have been welded tothe press head plate 628. However, it is also possible that the tubes630, 634, and 638 may be connected to a top mounting plate which ismounted to the press head plate 628. The block 622 is shown beingpositioned on a production board 642. The block 622 is being compressedin this particular position.

FIG. 24 shows the mold system 620 being completely stripped away fromthe block 622 during the manufacturing process. The block 622 is leftpositioned on the production board 642 to be further processed. Theblock 622 has a first tier 644, a second tier 646, and a third tier 648.By use of the mold system 620, the multilevel block 622 may bemanufactured.

As can be appreciated, the blocks 330, 400, and 450 of the presentdisclosure may be used for both commercial and residential use inbuilding various borders for a landscaped area. Numerous other designsor shapes for various borders for a landscaped area may be formed byusing the blocks 330, 400, and 450. Further, instructions for aparticular border may be provided with the blocks 330, 400, and 450 toassist in installation of the particular border. By using theinstructions, an individual or homeowner will be able to construct aborder quickly and easily, including square corners and other shapes.

Other advantages associated with the use of the mold system 10 includethe reduced number of different components or parts that need to bemanufactured, transported, stored, or inventoried. Since only one moldbox needs to be constructed to manufacture the blocks 330, 400, and 450to construct a border, manufacturing costs are significantly reduced. Inparticular, only having one mold box can reduce manufacturing costs.Further, with use of the blocks 330, 400, and 450 nearly all shapes andpatterns can be installed. The blocks 330, 400, and 450 also easy toinstall and various different shaped borders are capable of beingconstructed or installed. Other examples of borders that may beconstructed using the blocks 330, 400, and 450 of the present disclosureinclude borders around paths, sidewalks, floors, patios, steps, streets,and driveways, as well as a paver edging system. The mold system 10 isflexible in that different number of blocks may be manufactureddepending upon purchase orders or inventory requirements. For example,if more straight blocks 330 need to be manufactured then five mold boxinserts 16 may be placed on the mold box frame 14 and five plungerassemblies 30 may be placed on the press head plate 28. In thisparticular arrangement, ten of the blocks 330 will be manufactured at atime. It is also contemplated that a dedicated mold box frame 14 havingfive mold box inserts 16 that are bolted or secured to the mold boxframe 14 may be used. The mold system 10 allows for any combination ofthe blocks 330, 400, or 450 to be manufactured at a time. Further, if itis determined that the blocks 400 are very popular then a dedicatedpress head plate 28 having plunger assemblies 34 welded thereto may beused to continuously manufacture the blocks 400.

From all that has been said, it will be clear that there has thus beenshown and described herein a mold system for forming multilevel blockswhich fulfills the various advantages sought therefore. It will becomeapparent to those skilled in the art, however, that many changes,modifications, variations, and other uses and applications of thesubject mold system for forming multilevel blocks are possible andcontemplated. All changes, modifications, variations, and other uses andapplications which do not depart from the spirit and scope of thedisclosure are deemed to be covered by the disclosure, which is limitedonly by the claims which follow.

What is claimed is:
 1. A mold system for forming a multilevel blockcomprising: a first multilevel mold box insert for forming a firstmultilevel block, the first multilevel mold box insert having a bottom;a mold box frame adapted for receiving therein the first multilevel moldbox insert; a first multilevel plunger assembly comprising a topmounting plate, a first front pair of tubes connected to the topmounting plate and a first front mounting plate connected to the firstfront pair of tubes, and a first front press plate connected to thefirst front mounting plate, the first front press plate having athickness and a top, a first rear pair of tubes connected to the topmounting plate and a first rear mounting plate connected to the firstrear pair of tubes, and a first rear press plate connected to the firstrear mounting plate, the first rear press plate having a thickness, thefirst front pair of tubes and the first rear pair of tubes each having alength and both of the lengths being the same, the thickness of thefirst front press plate being greater than the thickness of the firstrear press plate, the differences in the thicknesses of the first frontpress plate and the first rear press plate adapted for allowing thefirst front press plate and the first rear press plate to be removedaway from the multilevel block when forming the multilevel block withoutremoving any material from the formed multilevel block and the top ofthe first front press plate not moving below the bottom of the firstmultilevel mold box insert for releasing the plunger assembly from themultilevel block; and a press head plate adapted for receiving thereonthe first multilevel plunger assembly.
 2. The mold system for forming amultilevel block of claim 1 wherein the multilevel mold box insertcomprises a back panel, a right side panel, a central panel, a left sidepanel, a front panel, and an upper central panel.
 3. The mold system forforming a multilevel block of claim 2 wherein the multilevel mold boxinsert further comprises a tab portion mounted to the right side panel.4. The mold system for forming a multilevel block of claim 2 wherein themultilevel mold box insert further comprises a tab portion mounted tothe left side panel.
 5. The mold system for forming a multilevel blockof claim 2 wherein the back panel comprises a pair of ends and a tabportion extending out from each of the ends.
 6. The mold system forforming a multilevel block of claim 2 wherein the front panel comprisesa pair of ends and a tab portion extending out from each of the ends. 7.The mold system for forming a multilevel block of claim 1 wherein themultilevel mold box insert comprises a back panel, a right side panel, afirst central panel, a second central panel, a left side panel, a frontpanel, and an upper central panel.
 8. The mold system for forming amultilevel block of claim 1 further comprising a second multilevelplunger assembly comprising a top mounting plate, a first front tubeconnected to the top mounting plate and a first front mounting plateconnected to the first front tube, and a first front press plateconnected to the first front mounting plate, a second front tubeconnected to the top mounting plate and a second front mounting plateconnected to the second lower tube, and a second front press plateconnected to the second front mounting plate, a first rear tubeconnected to the top mounting plate and a first rear mounting plateconnected to the first rear tube, and a first rear press plate connectedto the first rear mounting plate, and a second rear tube connected tothe top mounting plate and a second rear mounting plate connected to thesecond rear tube, and a second rear press plate connected to the secondrear mounting plate, the first front tube, the second front tube, thefirst rear tube, and the second rear tube each having a length and allof the lengths being the same, and the press head plate adapted forreceiving thereon the second multilevel plunger assembly.
 9. A moldsystem for forming multilevel blocks comprising: a pair of of multilevelmold box inserts each for forming a multilevel block and each having abottom; a mold box frame adapted for receiving therein each of themultilevel mold box inserts; a pair of multilevel plunger assemblies foreach of the multilevel mold box inserts, with one of the multilevelplunger assemblies comprising a top mounting plate, a first front tubeconnected to the top mounting plate, a first front mounting plateconnected to the first front tube, and a first front press plate havinga thickness and a top connected to the first front mounting plate, afirst rear tube connected to the top mounting plate, a first rearmounting plate connected to the first rear tube, and a first rear pressplate having a thickness connected to the first rear mounting plate withthe thickness of the first front press plate being greater than thethickness of the first rear press plate, the differences in thethicknesses of the first front press plate and the first rear pressplate adapted for allowing the first front press plate and the firstrear press plate to be removed from the formed multilevel blocks withoutremoving any material from the formed multilevel blocks and the top ofthe first front press plate not moving below the bottom of themultilevel mold box inserts for releasing the plunger assembly from themultilevel block; and a press head plate adapted for receiving thereoneach of the multilevel plunger assemblies.
 10. The mold system forforming multilevel blocks of claim 9 wherein one of the multilevel moldbox inserts comprises a back panel, a right side panel, a central panel,a left side panel, a front panel, and an upper central panel.
 11. Themold system for forming multilevel blocks of claim 10 wherein themultilevel mold box inserts further comprises a tab portion mounted tothe right side panel.
 12. The mold system for forming multilevel blocksof claim 10 wherein the multilevel mold box insert further comprises atab portion mounted to the left side panel.
 13. The mold system forforming multilevel blocks of claim 9 wherein one of the multilevel moldbox inserts comprises a back panel, a right side panel, a first centralpanel, a second central panel, a left side panel, a front panel, and anupper central panel.
 14. The mold system for forming multilevel blocksof claim 9 wherein the other one of the multilevel plunger assembliescomprises a top mounting plate, a first front pair of tubes connected tothe top mounting plate, a first front mounting plate connected to thefirst front pair of tubes, and a first front press plate having athickness connected to the first front mounting plate, a first rear pairof tubes connected to the top mounting plate, a first rear mountingplate connected to the first rear pair of tubes, and a first rear pressplate having a thickness connected to the first rear mounting plate, thethickness of the first front press plate being greater than thethickness of the first rear press plate.
 15. A mold system for formingmultilevel blocks comprising: a first multilevel mold box insert forforming a multilevel block of a first configuration and having a bottom;a second multilevel mold box insert for forming a multilevel block of asecond configuration and having a bottom; a mold box frame adapted forreceiving therein the multilevel mold box inserts; a first multilevelplunger assembly associated with the first multilevel mold box insert,the first multilevel plunger assembly comprising a top mounting plate, afirst front pair of tubes connected to the top mounting plate, a firstfront mounting plate connected to the first front pair of tubes, and afirst front press plate having a thickness and a top connected to thefirst front mounting plate, a first rear pair of tubes connected to thetop mounting plate, a first rear mounting plate connected to the firstrear pair of tubes, and a first rear press plate having a thicknessconnected to the first rear mounting plate, the thickness of the firstfront press plate being greater than the thickness of the first rearpress plate, the differences in the thicknesses of the first front pressplate and the first rear press plate adapted for allowing the firstfront press plate and the first rear press plate to be removed whenforming a first multilevel block without removing any material from thefirst multilevel block and the top of the first front press plate notmoving below the bottom of the first multilevel mold box insert forreleasing the first multilevel plunger assembly from the multilevelblock, and the first front pair of tubes and the first rear pair oftubes each having a length and both of the lengths being the same; asecond multilevel plunger assembly associated with the second multilevelmold box insert, the second multilevel plunger assembly comprising a topmounting plate, a first front tube connected to the top mounting plate,a first front mounting plate connected to the first front tube, and afirst front press plate having a thickness and a top connected to thefirst front mounting plat, a first rear tube connected to the topmounting plate, a first rear mounting plate connected to the first reartube, and a first rear press plate having a thickness connected to thefirst rear mounting plate, the thickness of the first front press platebeing greater than the thickness of the first rear press plate, thedifferences in the thicknesses of the first front press plate and thefirst rear press plate adapted for allowing the first front press plateand the first rear press plate to be removed when forming a secondmultilevel block without removing any material from the secondmultilevel block and the top of the first front press plate not movingbelow the bottom of the second multilevel mold box insert for releasingthe second multilevel plunger assembly from the multilevel block, andthe first front tube and the first rear tube each having a length andboth of the lengths being the same; and a press head plate adapted forreceiving thereon the multilevel plunger assemblies.
 16. The mold systemfor forming multilevel blocks of claim 15 wherein the firstconfiguration is a straight block.
 17. The mold system for formingmultilevel blocks of claim 15 wherein the second configuration is acurved block.